Externally applied zipper for reclosable bag

ABSTRACT

A reclosable bag is disclosed with a zipper sealed to the exterior surface of front and rear web panels. The interlocking elements of the zipper, prior to initial opening of the reclosable bag, are separated from each other by a removable header formed by lines of weakness immediately above the seal lines between the zipper flanges and the web panels. The initial opening of the bag is performed by tearing the lines of weakness and removing the header. This allows the interlocking elements of the zipper to interlock with each other for the subsequent reclosing of the bag. The zipper can be applied across the top of the bag or along a corner thereof.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a reclosable bag with an externallyapplied zipper. Prior to the initial opening of the bag, the profiles ofthe zipper are separated by the bag walls and are not engaged with eachother. However, perforations or other lines of weakness in the bagwalls, between the zipper flange to bag seal lines and the zipperprofile, allow the user to remove a header portion of the bag, therebyproviding an initial opening and allowing the profiles of the zipper toengage with each other for subsequent reclosing of the bag.

2. Description of the Prior Art

The prior art of reclosable bags is well-developed in many aspects, andhas generally been suitable for its intended purposes.

While corner openings of reclosable bags have been known in order tocreate a spout-like opening, such as disclosed in U.S. Pat. No.6,007,246 entitled “Reclosable Container Arrangement”, issued on Dec.28, 1999 to Kinigakis et al., the manufacturing and othercharacteristics of this reclosable bag have been open to improvement.

Likewise, reclosable bags, such as those disclosed in U.S. Pat. Nos.4,787,755 and 4,892,512, both to Branson, entitled “Reclosable FlexibleContainer Having Fastener Profiles Sealed at Their Ends to the Outsideof the Bag” and issued on Nov. 29, 1988 and “Method of Making ReclosableFlexible Containers Having Fastener Profiles Affixed to Exterior of BagWalls” and issued on Jan. 9, 1990, respectively, have beendisadvantageous in that the bag walls have been pinched between thezipper profiles when the zipper was closed. Additional prior artincludes U.S. Pat. No. 4,691,373 entitled “Zipper Closure with UnitaryAdhesive Cover Sheet” issued on Sep. 1, 1987 to Ausnit.

OBJECTS AND SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide areclosable bag wherein the product is contained by the package filmprior to initial opening, rather than relying on the internal strengthof the zipper profile.

It is therefore a further object of the present invention to provide areclosable bag wherein the film is not engaged between the zipperprofiles upon reclosing of the bag subsequent to initial opening.

It is therefore a still further object of the present invention toprovide a zipper configuration which can be adapted to a wide range ofpackage styles and package manufacturing processes.

These and other advantages are attained by providing a reclosableplastic bag wherein the zipper profiles are attached to the outside ofbag with the interlocking elements facing inwardly. Perforations orother lines of weakness are formed in the bag walls immediately upwardof the seal lines between the zipper flange and the bag walls. In thisconfiguration, the interlocking elements are separated from each otherby a removable portion of the bag walls prior to the initial opening ofthe reclosable bag. However, after the removable portion of the bagwalls is removed during the initial opening of the bag, the interlockingportions of the zippers may contact and interlock with each other toreclose the bag. This configuration may be formed along the entire topof a reclosable bag or may be formed at a top corner of a reclosablebag, particularly if a spout-like configuration is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the invention will become apparentfrom the following description and from the accompanying drawings,wherein:

FIG. 1 is a plan view of the first embodiment of the reclosable bag ofpresent invention, prior to the sealing of the zipper profiles along thetop thereof.

FIG. 2 is a cross-sectional view along plane 2-2 of FIG. 1.

FIG. 3 is a plan view of the first embodiment of the reclosable bag ofthe present invention, after the sealing of the zipper profile along thetop thereof, but prior to the initial opening of the reclosable bag.

FIG. 4 is a cross-sectional view along plane 4-4 of FIG. 3.

FIG. 5 is a detailed section of FIG. 4.

FIG. 6 is a plan view of the first embodiment of the reclosable bag ofthe present invention, subsequent to the initial opening of the bag bythe removal of the header by the consumer.

FIG. 7 is a cross-sectional view along plane 7-7 of FIG. 6 with thezipper profiles separated.

FIG. 8 is a cross-sectional view along plane 7-7 of FIG. 6 with thezipper profiles engaged with each other.

FIG. 9 is a front plan view of the second embodiment of the reclosablebag of the present invention, with the zipper and removable header (theperforated lines shown in phantom) diagonally across a top corner of thereclosable bag.

FIG. 10 is a front plan view of an alternative second embodiment of thereclosable bag, including a slider, of the present invention.

FIG. 11 is a front plan view of an alternative third embodiment of thereclosable bag, including a slider, of the present invention.

FIG. 12 is a schematic of a vertical form fill and seal apparatus forforming the reclosable bag of the present invention.

FIG. 13 is a schematic of a horizontal form vertical fill and sealapparatus for forming the reclosable bag of the present invention.

FIGS. 14A-14D are schematics of a first horizontal form horizontal fillmanufacturing process for forming the reclosable bag of the presentinvention.

FIGS. 15A-15C are schematics of a second horizontal form horizontal fillmanufacturing process for forming the reclosable bag of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicatelike elements throughout the several views, one sees that FIG. 1 is aplan view of a first embodiment of the reclosable bag 10 of the presentinvention, prior to the sealing of the zipper 12 thereto. FIG. 2 is across-sectional view thereof. Reclosable bag 10 includes front web panel14 and rear web panel 16, co-extensive with each other, sealed to eachother around the periphery thereof—top seal 18, side seals 20, 22 andbottom seal 24—thereby forming product containment area 100 therein. Bag10 can be initially provided empty or filled with product. Some seals18, 20, 22, 24 may be replaced by folds in some variations of theseembodiments. Front and rear web panels 14, 16 are formed from polymericfilm or similar material, including monolayer, co-extruded or laminatefilms, coated paper or multi-wall paper webs, as would be known to thoseskilled in the art. Lines of weakness 30, 32, such as perforated linesor score lines, are formed opposite to each other, across the width offront and rear web panels 14, 16, respectively, immediately downwardlyadjacent from, and parallel to, top seal 18. The portions of front andrear web panels 14, 16 above lines of weakness 30, 32 form removableheader 34. Removable header 34 may include a hang aperture (not shown).

As shown in FIGS. 3, 4 and 5, zipper 12 is formed from first profile 40and second profile 42. First profile 40 includes first flange 44 andmale interlocking element 46. Likewise, second profile 42 includessecond flange 48 and female interlocking element 50. First and secondflanges 44, 48 are sealed to the exterior of front and rear web panels14, 16, respectively, immediately downwardly adjacent to, and parallelto, lines of weakness 30, 32, respectively, along first and second seal(or joinder) lines 52, 54 so that the male and female interlockingelements 46, 50 face inwardly toward each other. First and second seallines 52, 54 are typically formed by heat sealing (in which case sealantresin may be placed on the interior of first and second flanges 44, 48)or by hot glue or other adhesive. Likewise, first and second seal lines52, 54 typically intersect with side seals 20, 22. Those skilled in theart will recognize further variations after review of this disclosure.

Zipper 12, which is applied to the bag 10 shown in FIGS. 1 and 2 inorder to form the bag 10 as shown in FIGS. 3, 4 and 5, is fed over theweb panels 14, 16 of bag 10. In these figures, the zipper 12 has beenpre-cut to a segment with the ends fused, or pre-stomped together alongrespective ends of the profiles along profile end seal lines 56, 58, butthe zipper 12 could likewise be supplied as unattached zipper halfsegments or could be fed from a continuous supply of zipper halves ormated zipper could be supplied and unmated prior to attachment.

As shown in FIGS. 4 and 5, with removable header 34 in place extendingabove zipper 12 and protruding between first and zipper profiles 40, 42,male interlocking element 46 is separated from female interlockingelement 50 by removable header 34.

However, as shown in FIGS. 6, 7 and 8, after removable header 34 isremoved, typically by the consumer, by tearing along lines of weakness30, 32, male interlocking element 46 has access to female interlockingelement 50. As shown in FIG. 7, interlocking elements 46, 50 may beseparated to allow access by the consumer to product containment area100. Likewise, as shown in FIG. 8, interlocking elements 46, 50 may beinterlocked by the consumer in order to reclose bag 10.

A second embodiment of reclosable bag 10 is shown in FIG. 9. Zipper 12and lines of weakness 30, 32 (shown in phantom) are diagonally acrosstop corner 60 of bag 10, typically at a forty-five degree angle, therebycausing removable header 34 to be triangular. This second embodimentoperates similarly to the first embodiment except that a spout-likeopening is formed in place of top corner 60 by the removal of header 34.

A variation of the second embodiment of reclosable bag 10 is shown inFIG. 10 wherein slider 62 is parked or stabilized on a portion of zipper12 which extends beyond side seal 18. In this configuration, typicallyno flanges would be formed above the interlocking elements 46, 50. Uponthe removal of header 34, slider 62 is free to move in the conventionalmanner as known to those skilled in the art, separating first and secondprofiles 40, 42 when moved in a first direction and interlocking firstand second profiles 40, 42 when moved in a second direction.

FIG. 11 illustrates the embodiment of the reclosable bag 10, similar tothat of FIG. 10, but with zipper 12 extending along the top edge of thereclosable bag 10 and extending beyond side 22 and including slider 62parked at the extended portion of zipper 12.

FIG. 12 illustrates vertical form fill and seal apparatus 200 for theformation of reclosable bag 10. Film 202 is wrapped around fill tube 204and lateral edges 206, 208 are sealed to each other to form front andrear web panels 14, 16. Cross-seal bar 210 typically forms top seal 18and bottom seal 24 (typically one operation of cross-seal bar formingone seal for a first bag and another seal for a subsequent bag) as wellas lines of weakness 30, 32. Zipper 12 is thereafter supplied from spool212, and pulled, driven or guided into place and sealed to film 202.

FIG. 13 illustrates a horizontal form vertical fill and seal apparatus300 for the formation of reclosable bag 10. Film 302 is supplied fromspool 304 and folded along the bottom to form front and rear web panels14, 16 (alternatively, separate spools could provide the film for frontand rear web panels 14, 16). Film 302 may be supplied with lines ofweakness 30, 32 pre-formed or formed shortly after the dispensing fromspool 304. Zipper 12 is supplied from spool 306 and sealed to film 302.While FIG. 12 illustrates zipper 12 being sealed along the bottom of theresulting folded film structure, zipper 12 could likewise be sealedalong the top edges of the folded film structure forming front and rearweb panels 14, 16. Product is supplied by vertical filling station 308and cross-seal bar 310 forms side seals 20, 22 and separates adjacentbags one from another (typically one operation of cross-seal bar 310forming one side seal for a first bag and another side seal for asubsequent bag and separating one bag from another).

A first horizontal form, horizontal fill manufacturing process isillustrated in FIGS. 14A-14D. A first single sheet of web, illustratedas rear sheet 16, is provided as illustrated in FIG. 14A. Product 102 isplaced thereon as illustrated in FIG. 14B. The first single sheet of webis then folded as shown in FIG. 14C to form front and rear sheets 14,16, or a second sheet of web, illustrated as front sheet 14, is providedas shown in FIG. 14D. The appropriate seals are formed and zipper 12 isattached.

Similarly, in FIG. 15A, two products 102 are provided between sheets ofweb 14, 16 and the appropriate seals are formed and the zippers 12attached as shown in FIG. 15B. Alternatively, the ends of a single sheetcan be folded over the products 100 so that the middle half of sheet ofweb forms the rear panel of two adjacent reclosable packages and the endquarters of the sheet of web form the front panels of two adjacentreclosable packages as shown in FIG. 15C.

Those skilled in the art will find many variations of the apparatusdisclosed in FIGS. 12, 13, 14A-D and 15A-C after review of the presentdisclosure.

Thus the several aforementioned objects and advantages are mosteffectively attained. Although preferred embodiments of the inventionhave been disclosed and described in detail herein, it should beunderstood that this invention is in no sense limited thereby and itsscope is to be determined by that of the appended claims.

1. A reclosable bag, including: a first web panel; a second web paneljoined to said first web panel; a zipper including a first profile and asecond profile, said first profile including a first interlockingelement and said second profile including a second interlocking element;said first profile being joined to an exterior of said first web panelwith said first interlocking element facing said first web panel andsaid second profile being joined to an exterior of said second web panelwith said second interlocking element facing said second web panel; andsaid first and second web panels including a removable portion, whereinsaid removable portion, prior to removal, separates said firstinterlocking element from said second interlocking element and wherein,after said removable portion has been removed, said first interlockingelement and said second interlocking element can interlock with eachother thereby reclosing said bag.
 2. The reclosable bag of claim 1wherein removal of said removable portion provides an initial opening ofsaid bag and subsequent interlocking of said first and secondinterlocking elements with each other provides a subsequent reclosing ofsaid bag.
 3. The reclosable bag of claim 2 wherein said removableportion is formed by at least one line of weakness in said first andsecond web panels.
 4. The reclosable bag of claim 2 wherein saidremovable portion is formed by a first line of weakness in said firstweb panel and a second line of weakness in said second web panel.
 5. Thereclosable bag of claim 4 wherein said first and second lines ofweakness are first and second perforated lines.
 6. The reclosable bag ofclaim 4 wherein said first and second lines of weakness are first andsecond scored lines.
 7. The reclosable bag of claim 1 wherein said firstand second web panels are co-extensive with each other and are joined toeach other around a periphery thereof.
 8. The reclosable bag of claim 7wherein at least a portion of the periphery of said first and second webpanels are joined to each other by sealing.
 9. The reclosable bag ofclaim 1 wherein said first and second web panels are formed from asingle sheet of web and at least a portion of the periphery of saidfirst and second web panels is formed by a fold therebetween.
 10. Thereclosable bag of claim 1 wherein said first zipper profile includes afirst flange and said second zipper profile includes a second flange.11. The reclosable bag of claim 10 wherein said first flange is joinedto said first web panel along a first joinder line immediately adjacentto said first line of weakness and said second flange is joined to saidsecond web panel immediately adjacent to said second line of weaknessalong a second joinder line.
 12. The reclosable bag of claim 10 whereinsaid first line of weakness is between said first joinder line and saidfirst interlocking element and said second line of weakness is betweensaid second joinder line and said second interlocking element.
 13. Thereclosable bag of claim 11 wherein said first and second lines ofweakness are formed opposite to each other and immediately adjacent andparallel to a side of said periphery of said first and second webpanels.
 14. The reclosable bag of claim 1 wherein said first and secondlines of weakness are formed opposite to each other and diagonallyacross a corner of said first and second web panels.
 15. The reclosablebag of claim 14 wherein said first and second lines of weakness form aforty-five degree angle with a portion of the periphery of said firstand second web panels.
 16. The reclosable bag of claim 14 wherein saidzipper includes a slider which, when moved in a first direction,separates said first and second interlocking elements and, when moved ina second direction, interlocks said first and second interlockingelements.
 17. The reclosable bag of claim 16 wherein, prior to removalof said removable portion, said slider is stabilized in a locationbeyond said periphery of said first and second web panels.
 18. Thereclosable bag of claim 1 wherein said first interlocking element ismale element and said second interlocking element is a female element.19. The reclosable bag of claim 1 wherein said removable portion, priorto removal, protrudes between said first and second profiles of saidzipper.
 20. The reclosable bag of claim 1 wherein said zipper includes aportion extending beyond said first and second web panels, and wherein aslider is mounted on said portion.